Transfer case
 

This clunk sound normal? Just usual driveline slop?
I rocked car forward/reverse and could hear sound from t-case
so, I pulled driveshaft. And this seems louder then normal
i get good “clunk” sound when I turn into driveway,

It moves freely and the clunk is when it hits the gear?

Is there any lube in the transfer case? I have only worked on Fords for the last 20 years and the Escape transfer case takes 80/90. That sounds dry to me. My daughter has an all wheel drive Chrysler mini van and it takes gear oil also in the transfer case.

I do believe the the third generation Escape 2014-2019?) takes 75/140 rear axle lubricant in the transfer case.

It takes 80/90 rear axle lubricant in the rear differential.

I have an Escape SE 2.0 2014 AWD and the above are what I have been using.

Sorry, I refer to gear lube as not engine oil. If there is a hypoid gear set it needs special lube, that is all. Pick your flavor based on load and use. “ Manufacturers recommendations are usually the minimum”.

The transfer case on awd 2002-2003 era vues has a ring/pinion. It has no chain. I do not know what they did in 2004 on. This is pic found online that shows bad ring/pinion.

with vue in park. I push it rearward slightly and hear clunk from t-case. I than pull it forward and hear clunk. This is with driveshaft removed.
https://cimg2.ibsrv.net/gimg/www.sat...aecb35603.jpeg

Ring and pinion = hypoid gear set. Transverse engine and transmission needs a ring and pinion to send power to a rear differential. No chains needed.
I suspect you will find something similar in your transfer case.

https://cimg4.ibsrv.net/gimg/www.sat...cd8fa334b.jpeg
IF it has no gear oil and makes noise, adding oil will not fix it. I have a used one but I really don’t want to replace it as a test. Due to work involved. I suppose I have no choice. IF I want to try and resolve issue.

How about checking to see if it has any lube in it?

Had to remove output flange to install t-case and i could feel 1/8” slop in/out on old one .
The new one had no slop.
Also with pinion nut removed.
Book say’s to torque pinion nut to 82 lbs.
16oz is spec i had 14oz oil
been a long time since I used 1-1/16” socket, 27mm socket?
and 17mm female hex on drain plug
1-7/16” axle nut.